CrossSECTION_26

CROSSSECTION

www.crosssection-online.com

THE FUGRO GROUP MAGAZINEMARCH 2014

Equipment and expertise - on site and on time

SURVEYS ANDINVESTIGATIONS

10

16

12

05

CROSS SECTION 26 I MARCH 2014 I 03

CROSSSECTION

As Fugro’s new pile top drill readies for action at a UK offshore wind farm development, this issue of Cross Section introduces the T120. Believed to be the biggest reverse circulation drill rig and drill bit in existence, it demonstrates Fugro’s drilling expertise and is set to prove its cost-saving capabilities. Cost-saving benefits are also assured with Fugro’s latest ROV simulation software developments and new components. DeepWorks™ ROV pilot training simulator now models all electric sub-systems with greater accuracy, reducing offshore testing time with enhanced ROV pilot training and validation scenarios. A proud recipient of several recent awards, Fugro has been recognised for innovative technology and its safety culture. Scoring double success in the ‘Spotlight on Technology’ awards, Fugro’s two recognised innovations include integrated 3D iceberg mapping, as featured in the centre pages. Stretching across the globe to Western Australia, Fugro’s exemplary safety practices and culture have led to awards from client Chevron and a rare platinum honour from IFAP. We’ll be bringing to life all of these Cross Section articles - and lots more - at major offshore exhibitions and conferences in Europe, the USA and Asia in the coming months, beginning with Oceanology International, where you’ll find us on stand E100. We look forward to meeting you.

Debra Barker - [email protected]

About Cross SectionWe are pleased to publish Cross Section Magazine for customers and other readers worldwide. Most of the articles are written by Fugro personnel who are, or have been, closely involved with the technology or project described; we invite you to contact them for further information using the email address included with the relevant article.

SubscribeSign-up online to receive email alerts when new issues of Cross Section are published. You can also view previous issues in our online archive or download PDF copies: www.crosssection-online.com

Alternatively scan the code using your smartphone.

Tell us what you thinkWe welcome your feedback on any aspect of the magazine or website and encourage you to send us your comments by email: [email protected]

COPYRIGHTMaterial in this magazine may not be reproduced without written permission from Fugro.

Welcome

On the coverWhen Fugro conducted a series of geophysical surveys in remote Greenland, the advantages of its air-shippable AUV were soon evident. Easy transportation on a standard passenger aircraft avoided the delays of delivery by sea, the system was rapidly mobilised and striking images of the seafloor of Baffin Bay were soon being produced.

WHAT’S NEW?04 Rare Platinum Award for Safety Exemplary safety practices and culture recognised

04 New ALB Software Reduces Delivery Time

05 Investment in New Training Centre Classroom training and hands-on field experience for Fugro’s new offshore survey recruits

05 Fugro in Mozambique: New Offices and Labs

06 Upgraded Electric ROV Simulator New electric ROV control pod and suite of components

TECHNOLOGY, TOOLS AND TECHNIQUES07 Working Deeper Deepwater oilfield support with unrivalled ROV expertise

08 Smarter Pipe-Soil Interaction Analysis SMARTPIPE® at the forefront of deepwater technology

09 Predicting Landfall of Cyclone Phailin

16 Measuring Data in The World’s Oceans

PROJECT REPORTS10 Icebergs on the Move Award-winning 3D profiling technology advances risk management in ‘iceberg alley’

12 Industrial Dimension Control 3D laser scanning produces digital models to support removal of two 53-ton condensers

12 How to Optimise the Lifetime of a Storage Tank

14 Mapping the Roof of the World Route investigations for a gas pipeline from China to the Turkmenistan- Uzbekistan border

16 Have AUV, Will Travel Air-shippable AUV easily transported for geophysical surveys in the remotest parts

OUR BUSINESS18 Expanding the Parameters of Drilling Technology Fugro’s tailor-made equipment meets all drilling challenges

Fugro provides the people, equipment, expertise and technology that support the exploration, development, production and transportation of the world’s natural resources. Clients are provided with the technical data and information required to design, construct and maintain structures and infrastructure in a safe, reliable and efficient manner.

CONTENTS

ALB Airborne LiDAR Bathymetry

AUV Autonomous Underwater Vehicle

CPCathodic Protection (technique used to control

corrosion of a metal surface)

CPT Cone Penetration Test

CTDConductivity, Temperature and Depth

(measurements)

DPDynamically Positioned (vessel’s position

automatically maintained by a computer-

controlled system)

EM Electromagnetic

FLI-MAP®Fugro’s airborne laser scanning system for

obtaining highly accurate topographic data

FLNG Floating Liquefied Natural Gas

HPHT High Pressure High Temperature (pipeline)

IFAPIndustrial Foundation for Accident Prevention.

Registered Training Organisation (Australia)

providing public and corporate courses

INS Inertial Navigation System (navigation aid)

JIP Joint Industry Project

LARS Launch And Recovery System

LASPublic file format for the interchange of 3D

point cloud data between users

LiDAR Light Distance And Ranging

LIM Line Impedance Monitor

MBES Multi-Beam Echo Sounder

ROV Remotely Operated Vehicle

T-barTool for measuring ground resistance of soft

soils using a ‘mini’ or ‘standard’ sized rod

USBLUltra-Short Baseline (underwater acoustic

positioning method)

GLOSSARY OF TERMS AND ABBREVIATIONS

04 I CROSS SECTION 26 I MARCH 2014

New ALB data processing software is set to reduce data delivery times to Fugro’s customers. The new software enables data collected using the Fugro LADS Mk 3 and Riegl VQ-820-G sensors to be viewed together and edited in spatial tiles using various interactive tools. Importantly, all the attributes of the LADS and Riegl data in LAS format are preserved, which facilitates efficient classification of the data and creation of products.

The software release forms phase 1 of a multi-phase data processing improvement plan to minimise technical risk and support customers of current projects and ALB system sales. Subject to water clarity, the LADS system provides coverage from the coastline to maximum depths of 80 metres; the Riegl system provides very high density coverage at up to 520 kHz (multiple points per square metre) in very shallow water and on land.

The combination of these sensors enables seamless data to be collected in the coastal zone with minimum infill. It is suitable for multiple applications - such as nautical charting, coastal zone management and tsunami modelling - as well as providing support to the oil and gas industry.

email > [email protected]

NEW ALB SOFTWARE REDUCES DELIVERY TIME

Fugro LADS senior software engineer Aaron McKenzie demonstrates the new software which enables LADS Mk 3 and Riegl VQ-820-G data to be viewed and edited together.

Located on the Helford River in Cornwall, UK, Fugro’s new training centre is addressing the training and development needs of its operational staff. With a rich marine industry infrastructure close at hand, as well as easy access to Falmouth Bay and the English Channel, the location is ideal for this marine training centre which includes office, quayside and workshop facilities.

The first course at the centre is Fugro’s new 12-week ‘Survey and Engineering Training’ programme - a practical course designed for its new offshore survey recruits and run by Fugro Academy, the initiative that facilitates staff training and development across the Fugro group. The course provides a mix of classroom-based training and hands-on field experience, using the centre’s two 9-metre

inshore survey vessels. It aims to give the delegates confidence and competence in the use of Fugro’s survey systems prior to their initial offshore deployment, developing the knowledge and skills they require to work offshore as a fully trained junior member of the survey team.

Four of these 12-week courses are planned for 2014, involving around 70 surveyors and survey engineers. Other plans for the future include further investment in teaching personnel, equipment and facilities, expanding the range of survey training courses and extending the well-equipped training facilities to all divisions of the Fugro group.


INVESTMENT IN NEW TRAINING CENTRE

TRAINING CENTRE

CORNWALL, UK

Fugro recently opened a new office in Maputo and established the only internationally accredited laboratory in Mozambique.

Continuing to meet the fast-growing demands of the country’s large-scale industries, the new facilities will support Fugro’s commitment to servicing its oil and gas clients in the region as well as further developing its business in Mozambique’s construction, mining and hydrogeological sectors.

Providing local access to Fugro’s network of global services and expertise, the main office in the port city of Maputo provides quick and efficient response to client requirements. In Pemba, the operational centre and laboratory are well served by road, air and sea connections and offer ISO 17025 accredited soil, chemical, electrical and materials testing and soil aggregate laboratory testing.

Committed to a progressive increase in the number of local Mozambican staff at its new facilities, Fugro’s emphasis on local involvement also extends to the materials, equipment, services and sub-contractors involved in its projects.


onshore and nearshore geotechnical and CPT testing

geotechnical engineering reporting

airport and pavement evaluation

diving and salvage services

offshore positioning and geospatial services

Fugro in Mozambique

FUGRO IN MOZAMBIQUE: NEW OFFICESAND LABS


“Fugro’s investment in the new centre gives our delegates true-to-life exposure to the practicalities of offshore survey but without the pressure and demands of doing so on live projects.”Andrew McNeill, Global Talent Development Manager

WHAT’S NEW?

At the 2013 IFAP/CGU Safe Way Awards ceremony in Perth, Australia, Fugro Survey was the proud recipient of a Platinum Award. Representing the highest level, the Platinum Safety Achievement Award is only attained after five consecutive Gold Awards. At the same event Fugro Spatial Solutions was presented with a Gold Award.

FUGRO SYNERGY TEAM ACHIEVEMENTS Working on the Gorgon LNG project in Western Australia, the Fugro Synergy team received awards from Chevron including ‘Best Contractor’ which recognised Fugro’s ongoing leadership and commitment to safety. During the project, Fugro’s senior management attended every project induction and every crew change at a site over 1,500 kilometres away from the office. Chevron noted the ‘advanced safety culture’ on board the vessel.

The team demonstrated commendable and visible leadership, accountability and support towards the delivery of an incident- and injury-free (IIF) offshore survey. The level of genuine care and concern for one another and outstanding use of ‘stop work authority’ was also recognised with an award.


Above and left: IFAP/CGU Safe Way Awards ceremony in Perth, Australia.

RARE PLATINUM AWARD FOR SAFETYFugro has recently been the proud recipient of a number of significant awards including a rare Platinum Award from IFAP. The awards recognise exemplary safety practices and culture.

WHAT’S NEW?

WHAT’S NEW? TECHNOLOGY, TOOLSAND TECHNIQUES

“Fugro brings an unrivalled combination of ROV design, construction and simulation expertise to the challenges of deepwater oilfield support.”Alan Anderson, Technical Manager, Fugro Subsea Services Limited

With the introduction of a new electric ROV control pod and suite of electric ROV-specific components, Fugro’s DeepWorks™ software now models all electric sub-systems with greater accuracy. DeepWorks™ ROV pilot training and mission-planning simulator uses real-time dynamic and hydrodynamic modelling to provide highly realistic training for subsea operations. Accurately modelled systems, operated through real control interfaces, offer pilots the same interactive experience as if they were actually operating the ROV or deploying a manipulator-held tool.

The software enables failure cases to be simulated on individual sensors and circuits and new vehicle configurations to

be assembled in a way that reflects their true circuit diagrams. The range of training scenarios is extended and more transparent testing and validation in the simulator can be undertaken before the vehicle enters service.

A new, easy-to-use overlay designer allows both scenario builders and training supervisors to quickly configure and manage overlays; it displays navigation and sensor information in exactly the same way as the real vehicle system. Crucial instrumentation data such as heading, pitch and roll as well as camera tilt angle reaches the overlay through the control pod.

Other enhancements include a new garage system as used by the Saab Seaeye observation class vehicles in Fugro’s fleet; this allows


UPGRADED ELECTRIC ROV SIMULATORPilot training and fault finding


WORKING DEEPERUnrivalled ROV expertise

Equipped with video cameras, sonars, pipe-trackers and navigation and positioning sensors, ROVs inspect pipelines and other subsea equipment where divers cannot operate whilst manipulators and intervention tools enable them to carry out maintenance at depths as great as 3,000 metres.

THE NEXT GENERATIONDesigned and built in-house, the FCV 3000 200HP Work Class ROV is capable of meeting the extreme demands of deepwater drilling and completions. It is suited to subsea oilfield and construction support as well as inspection, repair and maintenance of installations. Tooling packages can be rapidly installed by means of standard interfaces – both mechanical and control – which map any new sensors to the surface without the need for rewiring. These interfaces ensure safe and efficient operational changes.

At the heart of every FCV ROV is Fugro’s proven control and communications system based on single-mode, fibre-optic (SMFO) technology, including Fugro’s own designed and built SMFO multiplexer. This also gives exceptionally high data throughput and provides automatic switching in the event of a fibre failing.

This high-end multiplexer can manage up to twelve conventional cameras (eight simultaneously) and provides a wide range of data communication protocols, for efficient integration of add-on tools and sensors.

HIGHLY REALISTIC TRAININGFugro’s DeepWorks™ ROV pilot training and mission-planning simulator uses real-time dynamic and hydrodynamic modelling to provide highly realistic training for subsea operations. Accurately modelled thrusters, manipulators and tether management systems, operated through real control interfaces, offer pilots the same interactive experience as if they were actually operating the ROV or deploying a manipulator-held tool.

During complex offshore missions DeepWorks™ provides real-time situational monitoring of topside and subsea assets. Live visualisation of the entire field of operations with personalised views for vessel, crane and ROV support teams improves both efficiency and safety. Continuous recording of positional and engineering data provides a “black box” flight record of the entire mission to verify that installations or interventions were carried out in accordance with agreed procedures and conformed to manufacturers’ instructions.


“To be able to connect up a vehicle’s sub-systems through junction boxes and valve packs in the same way as the real vehicle puts us in a much stronger position to train not just piloting skills but also vehicle assembly and fault finding in a simulated environment. This way we can arm ROV designers and pilot technicians with a broader skillset.”Dr Jason Tisdall, Business Line Manager, Fugro Robotic Technologies

training on vehicle specific docking and undocking. Also included is a new CP measurement probe, deployed by either ROVs or divers, providing real-time CP measurement of both subsea pipelines and structures. A virtual CP field is detected, continuously displayed via the overlay and recorded within the simulation data for post mission analysis. Improved feedback to the console includes water detection, ground detect and LIM faults on circuits and sensors.



FCV 3000

THE DATA HIGHWAY HANDLES UP TO 24GB WHICH CAN RUN:

the ROV

the tether management system

3 HD cameras (optional)

full survey data suite (including multi-beam sonars)

a range of other specialist sensors

DeepWorks™ provides real-time simulation monitoring.

SMARTPIPE® from concept to construction

SMARTERPIPE-SOILINTERACTION ANALYSIS

2005Developed in collaboration with BP and the University of Cambridge to meet industry needs and improve understanding in terms of pipe-soil interaction. The challenge: to create an innovative technology that is able to measure pipe-soil interaction forces in the field.

2007System capability extends to measuring loads, excess pore water pressures and displacements during the movement of a real size pipeline section and in water depths up to 2,500 metres. Easily deployed from the deck of a geotechnical vessel, the SMARTPIPE® system allows remote control and real-time data acquisition.

2008-2009Extensive trials in soil conditions similar to those expected in deep waters; SMARTPIPE® equipment is deployed offshore. Fugro conducts two site investigations with BP, off the coast of West Africa. Investigations are conducted in very soft sediments in water depths greater than 2,000 metres. The huge amount of data collected is indispensable for the design of the HPHT oil pipelines, which will be interacting with challenging, very soft soil conditions for many years.

A custom-built LARS is developed for safe recovery of the SMARTPIPE® equipment.

SMARTPIPE® is the only commercially available in situ testing tool that characterises very soft soils in deep water with a real size pipeline section.

Fugro’s SMARTPIPE® consists of an integrated module which is fitted in a seabed frame. The module includes a standardised pipe section that directly measures the pipe-soil interaction forces in three dimensions. The pipe section instrumentation includes force sensors, displacement sensors and pore-water pressure sensors located along the pipe invert and circumference. Supplementary equipment includes a conventional or mini T-bar for shallow monotonic and cyclic soil testing or a CPT for shallow monotonic testing.

The instrumented pipe section consists of a polypropylene-coated steel pipe with interface roughness (Ra) of about 5 µm to 10 µm. Pipe loads, displacements and pore-water pressures during pipe movements are measured in real-time as a result of fibre optic cable.

Testing in the vertical and axial directions, monotonic and cyclic testing in the vertical direction up to 1.0 m stroke, monotonic or cyclic testing in the axial direction up to 0.5 m amplitude and lateral movements (for example, to mimic lay effects) can be modelled.

While the system was designed for very soft deepwater clays it has also performed well in silty carbonate sands at shallow water depths.


2012A site investigation offshore West Africa provides a pertinent dataset to better characterise the interaction between very soft sediments and infield flowlines. Testing focuses on studying key parameters known to influence the pipe-soil interaction response. A subsequent site investigation focuses on testing carbonate sands and clays offshore Western Australia. The SMARTPIPE® system is deployed from state-of-the-art geotechnical drillship Fugro Synergy to confirm the range of site-specific pipe-soil interaction parameters and justify optimistic assumptions made during the preliminary design phase.

Vital data from strategically located buoys recently helped Indian scientists read Cyclone Phailin with extraordinary accuracy.

The Very Severe Cyclonic Storm (VSCS) Phailin crossed Odisha and adjoining north Andhra Pradesh coast near Gopalpur, India, on 12th October 2013. With a sustained maximum surface wind speed of 200-210 km/hr, gusting to 220 km/hr, it caused extremely heavy rainfall; this led to floods and strong winds and resulted in large-scale structural damage, storm surges and coastal inundation.

Information on sea pressure, surface temperature and wind speeds collected by Fugro’s sea-borne platforms – SEAWATCH Wavescan buoys – was transmitted via satellite to meteorologists, analysts, programmers and researchers enabling the delivery of precise information on monsoon and weather systems in India.

The data helped to predict Cyclone Phailin’s potential impact four days before it arrived at Gopalpur, giving local authorities the crucial benefit of time to take pre-emptive action, saving thousands of lives.

Assessing the power and the likely path of tropical storms is increasingly important in assisting disaster management agencies. The availability of ocean observation data is allowing Indian agencies to examine developing weather systems and plan appropriately.


PREDICTING LANDFALL OF CYCLONE PHAILIN

Photo courtesy of Dundee Satellite Receiving Station

New testing sequences capture the potential for cycling hardening; effects of the laying dynamics and pipeline unloading; and axial resistance at slow pipe velocities. During 24 cumulative days of testing, with minimal downtime, SMARTPIPE® works continuously on the seabed for up to seven days.

To ensure smooth recovery of the SMARTPIPE® frame a dedicated cursor frame is developed.

Dedicated cursor frame for recovery.

CROSS SECTION 26 I MARCH 2014 I 09 08 I CROSS SECTION 26 I MARCH 2014

TECHNOLOGY, TOOLSAND TECHNIQUES


NEWFOUNDLAND

LABRADOR

QUEBEC

LABRADORSEA


Icebergs pose significant risk to vessels and oil and gas structures off the northeast coast of Canada and are routinely towed away from such development fields. Ice risk mitigation and management is essential to oil and gas activities in the region. Until now, iceberg impact analysis has been conducted on the basis of generalised iceberg shapes compiled from measurements taken over 20 years ago using technology available at the time.

In June 2012 Fugro went to ‘iceberg alley’ - offshore Newfoundland and Labrador - to track down and map these magnificent ice forms. The team was called upon to define icebergs in much more detail, contributing to Fugro’s client’s database of iceberg properties including size, shape, depth, height and surface variability. These properties are used in ice engineering to calculate mass, impact loads and seabed scouring characteristics.

More precise impact modelling and more accurate risk management can now be conducted with the larger sample and more detailed iceberg shape information resulting from Fugro’s work.

Multibeam sonar was selected as the primary tool to acquire data on the underwater portion of icebergs (keels), while a photogrammetry system was employed to map the above-water portion (sails) simultaneously. An ROV was mobilised with a dual-head multibeam system and a CodaOctopus Echoscope® and installed on a DP vessel; a pole-mounted multibeam was also installed and used for reconnaissance work and as a contingency to

ROV operations. Three high definition cameras were mounted at fixed offsets on the vessel and interfaced to Fugro’s Starfix navigation system for trigger synchronisation and recording of vessel dynamics.

SAILS AND KEELSAs the vessel and ROV circumnavigated the iceberg, the multibeam sonar acquired a time series of vertical profiles of the full iceberg wall while the Echoscope® provided overlapping 3D acoustic snapshots of ‘patches’ of the wall. Whilst the ROV mapped the iceberg keel, high definition photographs were used to map the iceberg sails. Commercial off-the-shelf software, ‘PhotoModeler,’ was used to create 3D point clouds of sails by point matching features in overlapping photographs. This software also helped to calculate the drift (and subsequently derive the rotation) of icebergs using the GPS positions and geometry of the vessel-mounted cameras.

A total of 35 icebergs were surveyed ranging in draft from 35 to 180 metres, with some perimeter lengths greater than one kilometre. A unique factor of this survey was that 31 of the icebergs were moving. In conventional marine survey applications the target (generally the seabed) is stationary and the mapping tool moves over the target. With both the target and the mapping tools in motion there were two challenges. The first was to model the motion of the iceberg as accurately as possible and the second was to develop a method to apply the motion. Accurately modelling and applying iceberg motion (drift and rotation) to the multibeam data was imperative as icebergs were found to drift three kilometres or more and rotate as much as 50 degrees (and change direction of rotation)

while being surveyed. Failing to account for these factors would distort the iceberg shapes beyond usefulness.

PRACTICAL AND SAFEIcebergs can break apart, split and roll without warning so modelling had to be done by remote sensing. Putting tracking devices on the iceberg was not a realistic option; employing an ROV enabled the survey sensors to get close to the icebergs while keeping the vessel and crew at a safe distance. Of numerous options evaluated for tracking iceberg motion, a method for photogrammetry using multiple cameras demonstrated success.

Two software elements were developed in-house: one to best fit the drift and rotation data using least squares adjustment techniques (involving statistical modelling, testing and validating) and another to ‘de-skew’ iceberg shapes (by transforming the multibeam ping data from the GPS reference frame to an iceberg reference frame). The same transformation algorithms were used to align the sail data with the keel data to produce the final 3D model.

FURTHER INTERESTIn addition to further advancing ice engineering and ice risk management, the data collected during the survey are of great interest to oceanographic and ice dynamics groups. The many by-products of the survey include: characteristics of ice/seabed interaction on grounded bergs; water temperature change near ice (near surface and at depth); iceberg drift rates and drift forecasting; and the groundwork to further develop knowledge of ice scour through repetitive scour mapping.


ICEBERGS ON THE MOVE

“ExxonMobil Canada Properties, as operator of the Hibernia Southern Extension Project, together with its Co-Venturer Chevron, Suncor, Statoil, Nalcor, the Canadian Hibernia Holding Corporation and Murphy Oil, supported this work as part of its Research and Development commitment for the Hibernia Southern Extension Project.”

ATC SPOTLIGHT ON ARCTIC TECHNOLOGY AWARD – DOUBLE WIN FOR FUGROFugro’s ice engineering work has been recognised with a Spotlight on Arctic Technology award at the Arctic Technology Conference in Houston, USA.

GeoSAR - Fugro’s innovative solution for mapping Arctic ice - also received the Spotlight award.

FIND OUT MORE: Cross Section 23 - ‘Reducing Risk in the Arctic’

Icebergs are routinely towed away from oil and gas infrastructure in development fields off the coast of Eastern Canada.

Did you know?

3D profiling advances risk management in ‘iceberg alley ’

The vessel sailed from St. John’s to as far north as 56° latitude off the coast of Labrador, surveying a total of 35 icebergs.

PROJECT REPORT

Storage Tank Diameter 15m to 76m with maximum short-term foundation pressure of 175 kPa

Storage Tank Type Cold tank - temperature < 70° C

Foundation Type Annular stone-ring, inner sand pad

Software Tools Plaxis 2D, LimitState:Geo, Fugro’s in-house software

Challenges Difficult ground conditions 1.25 km2 area Optimisation of foundations for various tank dimensions Setting up quality control and monitoring requirements for

the repair foundation

At a major tank farm in Antwerp, Belgium Fugro’s expertise produced technical specifications for foundation design, construction principles, quality control and monitoring requirements for foundation repair. With over 150 vertical steel storage tanks, it was essential for the tank farm owner to minimise the time they were out of use and maximise their operational lifetime.


HOW TO OPTIMISE THELIFETIME OF A STORAGE TANK

OPTIMISING FOUNDATION CAPACITYSince the foundation is supporting the load from the tank and its contents, optimising its capacity and design will significantly influence its performance. This can be achieved by designing the foundation to account for all possible loading conditions. In the case of tank renovation, the challenge is to take into account subsoil conditions which have previously been loaded - long-term loading from a tank generally improves the subsoil. However, this improvement does not necessarily guarantee future tank stability due to changes in loading conditions, such as when large settlements

“Thanks to Fugro’s specifications we are able to make the best possible foundation and had a suitable tool for inspection.”Evert Martens, QA/QC tank maintenance engineer, client representative

occur and backfill materials are added to raise the foundation level. This often-neglected fact can reduce the operational life of the tank or even lead to foundation failure.

CONTROLLING FUTURE SETTLEMENTSAdverse stresses in the tank shell can result from differential settlements, causing significant structural problems. Settlement is observed by measuring shell elevation along its perimeter during hydrotest, repair phase and operational period. Industry standards normally provide detailed guidance on assessing various settlements to maintain tank integrity;

Heat exchangers are used in industry for heating, cooling, condensing or evaporating gases or liquids. Replacing condensers is difficult because they are usually installed deep within the factory; and when they are 8 metres long and weigh 53 tons, expert help is essential, especially when working to tolerances of only a few millimetres.

When two gigantic ship condensers had to be replaced at Shell’s Moerdijk plant, Fugro’s experts were called in along with specialists from Fluor Consultants, Cofely, Vermeer Eemhaven and Mammoet.

Using 3D laser scanning Fugro produced digital models of the two installations, including the surrounding steel, concrete and piping. Fluor used this data to identify the best routes for removing the existing condensers and installing new ones. This also made it possible to determine which parts of the plant had to be dismantled or demolished in order to carry out the project.

The condensers are large, horizontal vessels measuring 8 x 4.5 x 2.5 metres, standing on a concrete foundation and a steel structure. On the top side there is a large, rectangular flange, which is joined to a turbine by a connecting piece. The turbine was not to be replaced, so the new condenser was to be installed under the existing flange of the connecting piece. To minimise the necessary infilling between

‘old and new’ and to complete the project as quickly as possible, dimensional accuracy had to be guaranteed to the nearest millimetre. The flange, which measures 1.5 x 2.5 metres, is at an angle and is offset from the centre line of the condenser. Fugro produced the required highly accurate measurements of the existing flanges of the old condensers and the connecting pieces beneath the turbines.

DIMENSION CONTROL Using the data, the manufacturer of the new condensers, Vermeer Eemhaven, was able to verify the drawings. Fugro subsequently carried out interim tachymetric control measurements on the newly built units enabling the production of a report using AutoCAD (dimension control) immediately after the on-site measurement. Once the condensers were ready, a ‘final as built’ measurement was carried out. This was done by performing a laser scan of the whole system and making tachymetric measurements of key points. The installations were then transported from the construction site in Rotterdam.

Meanwhile in the factory, a local survey base network was created and specific final checks were carried out to determine exactly how much infilling would be necessary after the condensers were put in place. Fugro then put a 3D model of the new condenser into position in a 3D visualisation. The data yielded by this process were relayed back to the local base at Shell and served as a reference for Fugro staff and operators from the Mammoet transport company when installing the new condensers.

At the Shell plant, Mammoet placed the two condensers on skids and, following Fugro’s instructions, ‘slid’ them into position within a single day. The positional accuracy was less than 2 millimetres and the height accuracy less than half a millimetre - within the client’s specifications. Thorough checking and measuring beforehand meant that less reworking was needed on site, thereby increasing safety and reducing turnaround time.


INDUSTRIALDIMENSION CONTROLMillimetre accuracy and 53 tons of steel

Alignment of new condenser.

however such guidance does not include the Percentage Allowable Settlement (PAS) that can be tolerated immediately after foundation repair. Specifying PAS after foundation repair or hydrotest allows control of foundation work, enforces quality construction work and provides sufficient margin for future deformation.

FOUNDATION QUALITY CONTROLAnother factor affecting the lifetime expectancy of tanks is the quality of the construction work. Enforcing foundation quality control during tank construction can maximise tank operational lifetime and such control should specify the methods, compliance testing quantity, acceptance criteria of the test methods and corrective action.

email > [email protected], [email protected]

Project Facts

Photo courtesy of Shell

Photo courtesy of Shell

PROJECT REPORT

As part of the phased approach, a geologic field verification study was performed to review and field check the desktop geohazard screening study findings along selected portions of the pipeline corridor. Experienced Fugro geologists undertook field reconnaissance and mapping in Tajikistan and Kyrgyzstan which resulted in refinements to the definition and extent of geohazards delineated in the desktop study, through increased geohazard mapping detail at key locations. This in turn improved confidence and specification of recommendations to CNPC on needs for further site-specific investigations.

A probabilistic seismic hazard assessment (PSHA) was completed by establishing a project-specific seismotectonic model characterising rates, magnitudes and style of faulting that impact the project area. PSHA calculations provided acceleration response spectra to guide design along the pipeline route for 475-, 975- and 2475-year return periods. The seismic hazard results were deaggregated to identify the key contributors to the hazard in terms of earthquake magnitude and distances to, and types of, seismogenic sources.

BOREHOLE DRILLING PROGRAMMEFugro provided a geohazard-focused borehole layout to optimise sampling of different geologic units and potential hazards. Recommendations for geotechnical borehole locations along Tajikistan and Kyrgyzstan segments utilised the desktop Quaternary geologic mapping as a data-driven framework to optimise the borehole drilling programme for subsurface data collection and correlation. Potential locations for critical infrastructure that required refined estimates of site response for seismic loading were also identified. The borehole programme recommendations considered future needs for geotechnical sampling methods and locations based on Fugro’s understanding of the variety of geologic conditions and potential hazards that may need further characterisation to fully assess pipeline constructability and reliability. Integrating the geohazard mapping results with the EM data reduced the number of boreholes required (compared to an evenly spaced drilling approach) while increasing the informational value of each borehole

location. This in turn produced significant schedule and cost efficiencies for CNPC, while maintaining a sound scientific approach to satisfy engineering input requirements.

“The results of Fugro’s LiDAR and EM aerial survey along with the geohazard investigation meet the basic requirements for the detailed design of the next step. It has helped to accelerate the process of project implementation and has provided a basis for future large, long distance pipeline digital construction and maintenance.”Mr Zhang Chi, Trans-Asia Gas Pipeline Project Manager, CNPC


MAPPING THE ROOF OF THE WORLDTrans-Asia Gas Pipeline Route Investigations


China National Petroleum Corporation (CNPC), one of the world’s largest oil companies, recently initiated the design and construction of a natural gas pipeline extending from China to the border between Turkmenistan and Uzbekistan.

The pipeline alignment through Uzbekistan, Tajikistan and Kyrgyzstan crosses one of the most active tectonic regions of the world. Fugro provided consultancy for a quick turn-around feasibility-level geohazards investigation and detailed topographical and geophysical data acquisition. To meet CNPC’s ambitious project schedule, an integrated data acquisition and interpretation plan was implemented utilising airborne data acquisition and remote sensing data interpretation services. The project commenced in May 2013 with all field activities completed by November 2013 and consultancy reports submitted in stages throughout the project.

The planned 900-kilometre pipeline route extends from west to east through a corridor bound by the Pamir Mountains and Tien Shan, also known as “The Roof of the World”; associated tunnels form part of the project. The initial project phase started in Tajikistan and extended into Kyrgyzstan while later phases extended into Uzbekistan.

AIRBORNE DATA ACQUISITIONAirborne platforms acquired topographic and geophysical data in Tajikistan and Kyrgyzstan, while LiDAR was used to acquire high resolution (1:2,000 scale) topographic information and EM survey methods collected geophysical data along the planned pipeline route. These data support ongoing construction planning and additional detailed geohazard characterisation.

Mounting the FLI-MAP® system on Russian Mi-8 helicopters for LiDAR surveys in Tajikistan and Kyrgyzstan presented one of several new challenges. Fugro’s engineers worked on site and adapted the laser equipment to this new platform using local resources for cost and schedule savings. Adapting the FLI-MAP® system to the Mi-8 helicopter will considerably increase the potential for use of the airborne laser scanning system, opening doors for surveying completely new territories. Fugro also established 80 pairs of concrete markers and 250 topographic markers and undertook river bathymetry surveys at planned pipeline crossings.

For the Tajikistan and Kyrgyzstan segments of the pipeline route a heliborne EM survey was implemented. Acquired data were processed daily in near real-time to provide estimates of soil thickness over bedrock and soil properties with depth along the alignment. The EM data was then integrated with desktop geohazard mapping to refine interpretations and guide borehole layout planning efforts.

GEOHAZARDSDesktop geohazard screening included performing 1:50,000 scale mapping of geohazards (faults, landslides and liquefaction) within a five kilometre-wide corridor centred on the proposed pipeline route as part of a fatal flaw desktop screening study. Geohazard maps, including Quaternary geologic units, active faults and slope failures, were prepared for CNPC as a near real-time interim deliverable to guide and make necessary modifications to pipeline alignment, including proposed LiDAR and EM flight routes based on the initial identification of hazards. In addition,

‘traffic light-style’ landslide and liquefaction susceptibility maps were produced to provide guidance for route refinement for hazard mitigation.


Fugro’s workscope included topographic and geophysical data acquisition, integrated with geohazard investigations.

GEOHAZARD EVALUATION OF PIPELINE SEGMENTS:

desktop geohazard screening

geologic field verification

PSHA

development of borehole programme recommendations

Key to the success of this geographically and logistically challenging project was the close collaboration among CNPC, Fugro teams and local government authorities, including Tajik Air, Fazo (Tajik Land Survey Authority), Supreme Air and Geoconsult Survey Agency in Kyrgyzstan.

PROJECT REPORT

TRANS-ASIAGAS PIPELINE


Fugro has measured data in water depths from five to over 3,000 metres and recently recorded simultaneous deployments in Africa, Australia, Azerbaijan, Brazil, Brunei, Germany, Ghana, Indonesia, Liberia, Malaysia, Mozambique, Norway, Oman, Philippines, South Africa, Suriname, UAE, UK, Uruguay, USA and Vietnam. Parameters measured include currents, waves, water level, temperature, conductivity, turbidity and dissolved oxygen.

A JIP underway in Suriname is reaping the benefits of access to Fugro’s extensive equipment pool – the largest commercially available in the world. The project, involving four operators, consists of four moorings deployed in water depths between 1,660 and 2,400 metres. As well as wide geographical coverage of measured data the JIP operators benefit from cost efficiencies in items such as vessels, logistics and fieldwork.

In Australia, Fugro has deployed a pair of current moorings for high resolution CTD measurements through the upper 200 metres. Data will be utilised to aid FLNG engineering design, detect internal waves and for model validation.

HIGH QUALITY DATA RETURNTogether with model validation, data is measured to support field development projects. Deployments can last up to 24 months and may comprise many moorings, as in the case of a pipeline route from a deepwater FPSO location to a coastal terminal.

As client operations move into deeper, harsher, more remote locations the importance of understanding metocean parameters increases. Fugro’s investment in new equipment continues to grow, along with methods for data transfer and display. “Working in such challenging environments poses a high risk in terms of loss or failing of equipment,” says Jonathan Ainley, Commercial Manager at Fugro GEOS. “Armed with expert knowledge of global oceanography, careful planning, well designed moorings and capable technical staff we ensure that our clients receive a high return of quality data.”


MEASURING DATA IN THE WORLD’S OCEANS

A team of AUV operators, surveyors and data processors from Fugro recently travelled to Baffin Bay, Greenland. Air-freighting its Echo Mapper II AUV system, the team conducted a series of high-resolution geophysical site surveys.

Good quality, high-resolution geophysical data provided by AUVs are increasingly in demand, particularly as worldwide energy exploration and production in deeper water continues to expand. Not only do they provide high-resolution data, multibeam echosounder bathymetry, side scan sonar seabed imagery and sub-bottom profiler imagery but, together with precise positioning, AUV surveys can also support geotechnical engineers with the information needed for risk assessment.

Comparatively few AUVs are in service around the world; this can cause significant backlogs in delivery or can mean that vessels equipped with AUVs need to travel prohibitive distances between job sites, particularly those in remote areas.

Air-shippable AUV system deployed for Greenland surveysHAVE AUV, WILL TRAVEL

“Despite limited knowledge of the seafloor morphology and a hazardous remote environment, the integrated team from Fugro bases in the UK and the USA successfully completed the AUV portion of all permitted site surveys. The survey yielded striking images of the seafloor and allowed the continuation of the environmental portion of the 2013 Baffin Bay Project.”John Wood, Project Manager, Fugro Survey Ltd

ECHO MAPPER II AUV

STANDARD PAYLOAD INSTRUMENTS:

Reson 7125 multibeam echosounder

EdgeTech ETPro 2000-C side scan sonar

EdgeTech SB214 chirp sub-bottom profiler system

Additional instruments added as required.

Echo Mapper II AUV enables Fugro to avoid such problems. It is designed to be disassembled, securely packaged in shipping crates and despatched for rapid mobilisation on vessels of opportunity around the world. At under 4 metres long and weighing about 500 kilogrammes, Echo Mapper II is easily transported by air freight on standard passenger aircraft.


AUV SURVEYS GREENLAND

Did you know?

In January 2014, Fugro had metocean moorings deployed simultaneously in over 20 countries.

Photo courtesy of Patricia Hinds Photography


OUR BUSINESS

Fugro’s unique offering underlies a solid history of successful exploration and construction projects, designing, building and operating equipment suitable for even the most hostile and technically demanding environments. A team of design and engineering professionals undertakes continual innovation and testing at its purpose-built premises in order to provide safe, effective and bespoke drilling solutions that meet the exacting requirements of every project.

Making up Fugro’s project teams are talented people who work closely with clients, partners and stakeholders in the capacity of principal contractor, subcontractor or as part of a joint venture.

OPERATIONAL SECTORS PROJECT EXAMPLES

Oil and gasAdapted downhole equipment at BP’s Shah Deniz field, Caspian Sea, to carry large diameter casings through 103m of water; drilled 27m into the seafloor to pin the seabed template

Offshore wind farmsInstalled foundation piles for the world’s first offshore wind farm of its type in Gotland, Sweden. Subsequent projects generally involve the installation of large diameter monopile foundations for wind turbines and met masts

Nuclear plants

Pioneered the first outfall shaft of its kind - in open sea with strong currents and 20m water depth - at Flamanville Power Station, Northern France. Using its largest and most powerful drill, a 63m deep, 6.5m diameter shaft in iron ore infused granite was created

Ports, harbours, jettiesA range of drilling services for port construction (including jetty pile installations) and maintenance from Cape Lambert, Australia to Gothenburg, Sweden

Fugro’s tailor-made equipment meets all drilling challenges

As the world’s leading overwater marine drilling contractor, Fugro applies its geotechnical services and specialist foundation solutions to worldwide projects in marine construction, renewable energy, oil and gas and mining.

SPECIALISING IN SHAFT AND PILE DRILLINGFugro has the largest known fleet of specialist pile-top rigs and the most recent addition is the powerful T120. It is the fifteenth pile top drill in the Fugro fleet and, with 120 tonnes of rotational torque, it is designed to assist in the installation of monopiles for offshore wind farm developments. The T120 is capable of drilling holes with diameters up to eight metres.

Weighing around 350 tonnes it is believed to be the biggest reverse circulation drill rig and drill bit in existence and Fugro completed this

design and build project in just seven months – two months ahead of schedule. The project also included a new conductor, constructed in lattice form, which allows the drilling assembly to be stacked vertically, saving valuable deck space. It can also be installed quickly as a single unit onto the pile, reducing mobilisation time.

T120 - READY FOR ACTIONBetween February and July, Fugro will operate the new T120 pile top drill at the Westermost Rough offshore wind farm. Located 8 kilometres

off the UK’s Yorkshire coast, the wind farm will contain thirty-five turbines of 6MW capacity. The 6.5 metre-diameter piles will be installed using the ‘drive, drill, drive’ technique pioneered by Fugro.

Together with Fugro’s engineering expertise and pioneering techniques, the T120 is expected to reduce the installation time for this wind farm development, along with associated costs.



EXPANDINGTHE PARAMETERS OF DRILLING TECHNOLOGY “Our drilling rigs and associated

equipment are custom built for specific markets and projects. We are constantly seeking to expand the parameters of drilling technology.”Alun Jones, Fugro Seacore Ltd

Fugro Head OfficePO Box 412260 AA LeidschendamThe Netherlands

T: +31 (0)70 311 1422E: [email protected]

To subscribe to an electronic version of Cross Section, visit www.crosssection-online.com

CrossSECTION_26

Documents

Transcript of CrossSECTION_26